AEC 模温机控制器说明.pdf

Advanced Microprocessor Controller Chapter 1 Safety 1 of 64 Advanced Microprocessor Controller Part Number 682 62012 00 Bulletin Number AE1 630 3 Effective 10 22 04 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2006 All rights reserved Advanced Microprocessor Controller 2 of 64 Chapter 1 Safety Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list In addition to the equipment itself you should have Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Component instruction manuals if applicable Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For shipments in the United States and Canada call 1 800 423 3183 for all other countries call our international desk at 847 273 7700 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Advanced Microprocessor Controller Chapter 1 Safety 3 of 64 Table of Contents CHAPTER 1 SAFETY 6 1 1 How to Use This Manual 6 Safety Symbols Used in this Manual 6 1 2 Warnings and Precautions 7 1 3 Responsibility 7 CHAPTER 2 FUNCTIONAL DESCRIPTION 9 2 1 Models Covered in This Manual 9 2 2 General Description 10 2 3 Standard Features 11 2 4 Optional Features 11 2 5 Panel Layout and Keypad 12 LED Indicator Lights 12 LCD Display 12 LCD Messages 13 Keypad 14 2 6 Menu Structure 16 Primary Menu 16 Secondary Menu 16 Secure Menu 16 2 7 Passwords and Security 17 CHAPTER 3 INSTALLATION 19 3 1 Location 19 3 2 Electrical Connections 19 CHAPTER 4 BASIC OPERATION 21 4 1 Turning the Power On 21 4 2 Starting and Stopping Water TCUs 22 Starting the Unit 22 Stopping the Unit 22 4 3 Starting and Stopping Hot Oil TCUs 23 Starting the Unit 23 Stopping the Unit 23 4 4 Tuning 24 Autotuning 24 Manual Tuning Zeigler Nichols PID Method 25 4 5 Selecting a Local Probe 26 Using a Remote Input Probe for Monitoring 26 4 6 Setting Up Cascade Control 27 4 7 Adjusting the Automatic Venting Timer 28 4 8 Using Crash Cool 28 CHAPTER 5 ADVANCE OPERATION 29 5 1 Using the Analog Remote Input 29 Advanced Microprocessor Controller 4 of 64 Chapter 1 Safety 5 2 Retransmission Analog Signal 30 Setting the Analog Signal Source to FLOW 31 Using Analog Output for Heating and Cooling 31 5 3 Using the Flow Monitor 32 5 4 Programming the Alarms 33 Temperature 33 Flow Alarm 34 Open Sensor 34 Low Pressure 34 Low Fluid Level Alarm 35 High Fluid Level Alarm 35 Pump Failure Alarm 35 Safety Thermostat Alarm 35 Welded Contactor Alarm 35 5 5 Using the Second Setpoint Function 36 5 6 Using the Remote Start Function 36 5 7 Changing the Temperature Display Units 37 5 8 Setting the Temperature Display Precision 37 5 9 Using the Elapsed Time Meter 38 5 10 Programming Ramp Soak 39 Controlling Ramp Soak 41 Monitoring Ramp Soak 41 5 11 Setting the Approach Rate 42 5 12 Level Input Operation Water Units 42 5 13 Adjusting the LCD Display Contrast 42 5 14 Calibrating the T C RTD and V Inputs 43 5 15 Accessing the Debug Menu 45 5 16 Reloading Factory Defaults 46 5 17 Serial Communications Operation 47 Port Address 47 Baud Rate and Data Format 47 Protocols 47 MODBUS Protocol 48 SPI Protocol 51 CHAPTER 6 TROUBLESHOOTING 53 6 1 Operating Mode and Error Display Messages 55 CHAPTER 7 APPENDIX 56 7 1 Warranty 56 Technical Assistance 57 Parts Department Error Bookmark not defined Service Department Error Bookmark not defined Sales Department Error Bookmark not defined Contract Department Error Bookmark not defined 7 2 Menu Structure 58 7 3 Control Board Layout 62 7 4 DAC Board Layout Optional 62 7 5 Electrical Specifications 63 General 63 Advanced Microprocessor Controller Chapter 1 Safety 5 of 64 Normal Operating Environment 63 Storage Environment 63 Primary Power Supply Line Power 63 Alarm Outputs 63 External System Outputs 63 User Interface 63 Temperature Sensor Inputs 64 Flow Sensor Inputs 64 System Inputs 64 Optional Analog Output Modules 64 Advanced Microprocessor Controller 6 of 64 Chapter 1 Safety Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and optional features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the equipment We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the equipment These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the equipment safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your equipment provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics and parts lists A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death Danger DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning WARNING indicates a potentially hazardous situation or practice which if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice which if not avoided may result in minor or moderate injury or in property damage Advanced Microprocessor Controller Chapter 1 Safety 7 of 64 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power When welding or brazing in or around this equipment make sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed Refrigeration systems can develop refrigerant pressures in excess of 500 psi 3 447 5 kPa 34 47 bars DO NOT CUT INTO THE REFRIGERATION SYSTEM This must be performed by a qualified service technician only Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor Advanced Microprocessor Controller Chapter 2 Functional Description 9 of 64 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for the Advanced Microprocessor Controller The Advanced Microprocessor Controller is available for use with several models of temperature control units TCUs A separate manual describes operation installation and maintenance instructions for the TCU itself Advanced Microprocessor Controller 10 of 64 Chapter 2 Functional Description 2 2 General Description The Advanced Controller is a microprocessor based process controller designed for use with temperature control units The Advanced Controller monitors and maintains the temperature of the fluid in any given process to a selected setpoint using a unique proportional integral derivative PID auto tuning program The controller employs PID algorithms to automatically tune the system to heat or cool the fluid as required by the process The Advanced Controller has a Liquid Crystal Display LCD that provides all operational status and programming menus The controller includes self diagnostics to check hardware functions All diagnostic information is displayed in the second line of the Liquid Crystal Display The Advanced Controller is panel mounted and has a membrane keypad with tactile feedback When properly installed with a sealing gasket the Advanced Controller meets NEMA 4 or IP66 integrity Advanced Microprocessor Controller Chapter 2 Functional Description 11 of 64 2 3 Standard Features PID Control for both heating and cooling 4 line x 20 character LCD Display Screen Setpoint To Process From Process and DT displays System status Password protection Selectable sensor types Type K J 100 ohm and 1000 ohm RTDs Autovent sequence adjustable from 1 to 10 minutes Sixteen segment Ramp Soak program Start stop vent and alarm silence switches D C dry contact inputs for pressure switch pump rotation phase loss safety thermostat second setpoint remote start weld contact and for pump tank applications high and low water level Cascade control with remote input sensor Triac outputs for heating and cooling Crash Quick cool feature Alarm outputs for temperature absolute and deviation low or high flow with optional flow meter open temperature sensor low water pressure pump failure over temperature contactor weld high and low water level for pump tank units Analog setpoint temperature input current or voltage 2 4 Optional Features Analog output for heating SCRs and cooling modulating valves Analog retransmission of Setpoint or To Process temperature Analog retransmission of flow with optional flow meter Flow sensor input pulse or analog with voltage excitation RS 232 or RS 485 Modbus communications RS 485 SPI communications Advanced Microprocessor Controller 12 of 64 Chapter 2 Functional Description 2 5 Panel Layout and Keypad See Figure 1 on page 15 for an illustration of the control panel and its buttons The LCD backlight lights up whenever any key is pressed The backlight turns off after five minutes if no other key activity occurs LED Indicator Lights The Advanced Controller has one LED that will light up to indicate the control process has been started This LED is located inside the Start button of the controller s front panel When power is applied the LED will remain off until the Start button is pushed The LED will then illuminate green LCD Display A 4 line by 20 character liquid crystal display LCD will show operational status alarms and programming menus 1st Line The first line of the LCD continuously displays the To Process temperature 2nd Line The second line of the LCD continuously displays the Setpoint temperature 3rd Line The third line of the LCD continuously displays the From Process temperature the delta temperature of the To Process and the From Process and the flow in GPM or LPM if applicable 4th Line The fourth line of the LCD will display all menu items used in the controller setup Also displayed are the status of the pump outputs for the heater as well as cooling and elapsed time for the vent cycle The fourth line will also explain all alarm conditions and operating status Advanced Microprocessor Controller Chapter 2 Functional Description 13 of 64 LCD Messages Autotuning Appears while tuning is in process High Water Alarm Appears if the option is selected and the switch is closed Water Pressure Low Level Alarm Appears when the Low Water Pressure switch is open or the optional Low Water switch is closed Auto Vent Indicator Appears in the LCD display when the unit is in Auto Vent mode The vent time remaining will also be displayed Pump Rotation Loss Indicator Appears in the LCD display when the Pump Rotation switch is open Safety Thermostat Indicator Appears in the LCD display when the Safety Thermostat switch is open To Process Sensor Open Indicator 999 appears in the process LED displays when the To Process probe is open From Process Sensor Open Indicator 999 appears in the LCD display for return temperature RT when the From Process probe is open Remote Probe Sensor Open Indicator 999 appears in the LCD display for mold temperature MT when the Remote probe is open High Alarm Indicator Appears in the LCD display when a High Alarm condition occurs Low Alarm Indicator Appears in the LCD display when a Low Alarm condition occurs From Process Temp Indicator Appears in the LCD display when the temperature display is showing the To Process temperature Delta Temp Indicator Appears in the LCD display when the temperature display is showing temperature differential High Heat Output Indicator Displays status in the LCD display when full power heat output is applied Low Heat Output Indicator Displays status in the LCD display when half power heat output is applied When the optional proportional output is installed the display will show the percentage of output Cool Output Indicator Displays status in the LCD display when the cool output is applied When the optional proportional output is installed the display will show the percentage of output Ramp Soak Indicator Displays the ramp soak segment status and remaining time in the LCD display Second Setpoint Remote Start Displays status in the LCD display when either function is selected Communications Local Remote Weld Contact Appears in the LCD Display when a Weld Contact Alarm condition occurs Advanced Microprocessor Controller 14 of 64 Chapter 2 Functional Description Keypad Four keys Index Up Down and Enter are used primarily to gain access to the menu structure and modify the controller s parameters and features The remaining six keys are used to direct the controller to start or stop a process Button Function Index Used to advance to one of the three setup menus Used to advance to the next menu item when in a setup mode Used in conjunction with the Down button to go back to a previous menu item when in a setup mode Used in conjunction with the Enter button at power on to break into Factory mode Up Used to increment the current setpoint value while system is in the normal running mode Note that the rate speeds up when the key is held down Used to increment the current parameter value when in a setup mode Note that the rate speeds up when the key is held down If press